2002 YAMAHA BT1100 clutch

OPERATION AND IMPORTANT RIDING POINTS
1
5
4
3
2
N
1
EAU01258
Starting a warm engine
Follow the same procedure as for starting
a cold engine with the exception that the
starter (choke) is not required when the
engine is warm.
EAU00423
Shifting
Shifting gears lets you control the amount
of engine power available for starting off,
accelerating, climbing hills, etc.
The gear positions are shown in the illus-
tration.
NOTE:
To shift the transmission into the neutral
position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
EC000048
•Even with the transmission in the
neutral position, do not coast for
long periods of time with the
engine off, and do not tow the
motorcycle for long distances. The
transmission is properly lubricat-
ed only when the engine is run-
ning. Inadequate lubrication may
damage the transmission.
•Always use the clutch while
changing gears to avoid damaging
the engine, transmission, and dri-
ve train, which are not designed to
withstand the shock of forced
shifting.
CAUTION:
5-3
5
1. Shift pedal
N. Neutral position
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6
Owner’s tool kit .............................................................. 6-1
Periodic maintenance and lubrication chart .................... 6-2
Removing and installing panels ...................................... 6-5
Checking the spark plugs ................................................ 6-5
Engine oil and oil filter element ........................................ 6-7
Final gear oil .................................................................... 6-9
Cleaning the air filter element .......................................... 6-10
Adjusting the carburetors ................................................ 6-12
Adjusting the engine idling speed .................................... 6-12
Adjusting the throttle cable free play................................ 6-13
Adjusting the valve clearance .......................................... 6-13
Tires ................................................................................ 6-14
Cast wheels .................................................................... 6-16
Adjusting the clutch lever free play .................................. 6-17
Adjusting the brake pedal position .................................. 6-18
Checking the front and rear brake pads .......................... 6-19
Checking the brake fluid level .......................................... 6-19
Changing the brake fluid .................................................. 6-21
Adjusting the shift pedal position .................................... 6-21
Checking and lubricating the cables ................................ 6-22Checking and lubricating the
throttle grip and cable ...................................................... 6-22
Checking and lubricating the brake and shift
pedals .............................................................................. 6-23
Checking and lubricating the brake and
clutch levers .................................................................... 6-23
Checking and lubricating the sidestand .......................... 6-24
Checking the front fork .................................................... 6-24
Checking the steering ...................................................... 6-25
Checking the wheel bearings .......................................... 6-25
Battery ............................................................................ 6-26
Replacing the fuses ........................................................ 6-28
Replacing the headlight and auxiliary light bulb .............. 6-29
Replacing a turn signal light bulb .................................... 6-31
Replacing the tail/brake light bulb .................................... 6-31
Replacing the license plate light bulb .............................. 6-32
Front wheel ...................................................................... 6-32
Rear wheel ...................................................................... 6-33
Troubleshooting .............................................................. 6-35
Troubleshooting chart ...................................................... 6-36
PERIODIC MAINTENANCE AND MINOR REPAIREAU00462

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
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Periodic maintenance and lubrication chart
NOTE:
•The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
•From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
•Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
6-2
6
ODOMETER READING (x 1,000 km)ANNUALN0. ITEM CHECK OR MAINTENANCE JOB
1 10203040CHECK
1*Fuel line•Check fuel hoses and vacuum hose for cracks
√√√√ √or damage.
2*Fuel filter•Check condition.√√
•Check condition.
√√
3 Spurk plugs•Clean and regap.
•Replace.√√
4
*Valves•Check valve clearance.
√√√√•Adjust.
5 Air filter element•Clean.√√•Replace.√√
6 Clutch•Check operation.
√√ √√ √
•Adjust.
•Check operation,fluid level and vehicle
for fluid leakeage. √√ √√ √ √
7*Front brake
(See NOTE on page 6-4).
•Replace brake pads. Whenever worm to the limit

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
EC000072
•In order to prevent clutch slippage
(since the engine oil also lubri-
cates the clutch), do not mix any
chemical additives with the oil or
use oils of a higher grade than
“CD”. In addition, do not use oils
labeled "ENERGY CONSERVING II"
or higher.
•Make sure that no foreign material
enters the crankcase.
CAUTION:6. Start the engine, and then let it idle for
several minutes while checking it for
oil leakage. If oil is leaking, immedi-
ately turn the engine off and check for
the cause.
NOTE:
After the engine is started, the engine oil
level warning light should go off if the oil
level is sufficient.
EC000067
If the oil level warning light flickers or
remains on, immediately turn the
engine off and have a Yamaha dealer
check the vehicle.
7. Turn the engine off, and then check
the oil level and correct it if neces-
sary.
NOTE:
Have a Yamaha dealer replace the oil filter
element when necessary.
CAUTION:
1. Engine oil drain bolt
6-8
6
1
4. Install the engine oil drain bolt, and
then tighten it to the specified torque.
5. Add the specified amount of the rec-
ommended engine oil, and then in-
stall and tighten the oil filler cap. Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.0 L
With oil filter element
replacement:
3.1 L
Total amount (dry engine):
3.6 L

EAU00462PERIODIC MAINTENANCE AND MINOR REPAIR
2
1
c
b
a
Ride at moderate speeds after changing a
tire since the tire surface must first be “bro-
ken in” for it to develop its optimal charac-
teristics.
1. Locknut
2. Free play adjusting bolt
c. Clutch lever free play
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Adjusting the clutch lever
free play
The clutch lever free play should measure
5-10 mm as shown. Periodically check the
clutch lever free play and, if necessary, ad-
just it as follows.1. Loosen the locknut at the clutch lever.
2. To increase the clutch lever free play,
turn the adjusting bolt in direction a.
To decrease the clutch lever free play,
turn the adjusting bolt in direction b.
3. Tighten the locknut.
NOTE:
If the specified free play cannot be
obtained as described above or if the
clutch does not operate correctly, have a
Yamaha dealer check the internal clutch
mechanism.
6-17
6

PERIODIC MAINTENANCE AND MINOR REPAIR
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Checking and lubricating the
brake and shift pedals
The operation of the brake and shift pedals
should be checked before each ride, and
the pedal pivots should be lubricated if
necessary.
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Checking and lubricating the
brake and clutch levers
The operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lubri-
cated if necessary.
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6-23
6
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)

SPECIFICATIONSEAU01038
8-1
8
Specifications
ModelBT1100
Dimensions
Overall length 2,200 mm
Overall width 800 mm
Overall height 1,140 mm
Seat height 812 mm
Wheelbase 1,530 mm
Ground clearance 168 mm
Minimum turning radius 2,980 mm
Basic weight
(with oil and full fuel tank)250.5 kg
Engine
Engine type Air-cooled 4-stroke,
SOHC
Cylinder arrangement V type 2-cylinder
Displacement 1,063 cm
3
Bore x stroke 95.0 x 75.0 mm
Compression ratio 8.3 : 1
Starting system Electric starter
Lubrication system Wet sumpEngine oil
Ty p e
Recommended API Service SE, SF, SG or
engine oil classification higher
Be sure to use motor oils that do not contain anti-friction modifiers.
Passenger car motor oils (often labeled “ENERGY CONSERVING II”)
contain anti-friction additives which will cause clutch and/ or starter
clutch slippage, resulting in reduced component life and poor
engine performance.8
Quantity
Without oil filter
cartridge replacement 3.0 L
With oil filter cartridge
replacement 3.1 L
Total amount
(dry engine) 3.6 L
CAUTION:
-20-10 0 1020304050°C
SAE 10W-30
SAE 10W-40
SAE 20W-40
SAE 15W-50
SAE 15W-40

SPECIFICATIONSEAU01038
8-2
8
Final gear oil
Type Hypoid gear oil SAE 80
(API GL4) or multigrade hypoid
gear oil SAE 80W-90
Quantity 0.2 L
Air filterDry type element
Fuel
Type Regular unleaded gasoline
Fuel tank capacity 20 L
Fuel reserve amount 5.8 L
Carburetor
Manufacturer MIKUNI
Model x quantity BSR37 x 2
Spark plug
Manufacturer/model NGK / BPR7ES or
DENSO / W22EPR-U
Gap 0.7–0.8 mm
Clutch type Wet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction
ratio 1.660
Secondary reduction
system Shaft drive
Secondary reduction
ratio 2.875
Transmission type Constant mesh 5-speed
Operation Left footGear ratio 1st2,353
2nd1,667
3rd1,286
4th1,032
5th0,853
Chassis
Frame type Twin tube Backbone
Caster angle 25°
Trail 106 mm
Tires
Front
Type Tubeless
Size 120/70-ZR17 (58W)
Manufacturer/ Dunlop / D205F TL
model Metzeler / MEZ3F TL
Rear
Type Tubeless
Size 170/60-ZR17 (72W)
Manufacturer/ Dunlop / D205 TL
model Metzeler / MEZ3 TL
Maximum load* 200 kg